Laser cladding: ib txoj kev rov ua dua tshiab ntsuab uas txhaj "super armor" rau hauv cov cav thee
Hauv qab qhov tob ntawm cov chaw khawb thee, cov kab txhawb nqa hydraulic hauv cov tshuab khawb thee uas siv tshuab tag nrho oscillate nyob rau hauv 10,000-tuj siab, scraper conveyor troughs sib tsoo tawm tsam cov thee gangue, thaum cov hydraulic cylinders tawm tsam kom ua haujlwm hauv cov chaw noo thiab corrosive. Cov khoom tseem ceeb no tsim cov "steel framework" ntawm kev ua haujlwm khawb thee, nyiaj dhau kev hnav tsis tu ncua, corrosion, thiab kev cuam tshuam rau lub sijhawm ntev. Cov txheej txheem txij nkawm ib txwm muaj xws li overlay welding, chromium plating, lossis hloov pauv tag nrho tsis yog tsuas yog ua pov thawj kim thiab siv sijhawm ntau tab sis kuj tsis ua tiav cov kev xav tau ntawm kev khawb thee niaj hnub rau kev ua haujlwm zoo, qis carbon, thiab tus nqi tsim nyog. Kev tshwm sim ntawm laser cladding technology tam sim no tab tom coj mus rau hauv "steel regeneration revolution" ntsiag to rau kev lag luam tshuab thee.
I. Laser cladding: "kev phais mob precision" ntawm kev tsim kho tshuab thee
Laser cladding tsis yog ib qho yooj yim "zaj duab xis" ntawm qhov chaw, tab sis yog ib qho thev naus laus zis tshiab uas tsim cov pas dej me me ntawm qhov chaw ntawm cov khoom siv nrog lub zog laser siab thiab tib lub sijhawm txau cov hmoov hlau tshwj xeeb kom ua tiav kev sib txuas ntawm cov hlau ntawm cov txheej cladding thiab lub hauv paus. Nws lub ntsiab lus tseem ceeb yog:
Kho lub hom phiaj kom meej: Lub teeb laser tuaj yeem muab tso rau qhov chaw kom raug rau hnav cov grooves thiab cov qhov corrosion, zam kev puas tsuaj rau cov substrate noj qab haus huv, tshwj xeeb tshaj yog tsim rau kev kho cov qhov tsis zoo hauv zos xws li khawb ntawm cov hydraulic kem thiab khawb ntawm phab ntsa sab hauv ntawm cov thooj voos kheej kheej.
Kev sib txuas ua los ntawm cov hlau muaj zog thiab tawv: Cov txheej cladding thiab lub matrix tsim atomic diffusion fusion, lub zog sib txuas yog txog li 400MPa, tshem tawm tag nrho cov kev pheej hmoo ntawm chromium plating peeling.
Kev ua tau zoo raws li qhov xav tau: Los ntawm kev xaiv cov hlau cobalt uas tsis yooj yim hnav (xws li Stellite 6), cov hlau nickel uas tsis yooj yim xeb lossis cov khoom siv tungsten carbide uas muaj zog, lub peev xwm ciaj sia ntawm cov khoom hauv cov xwm txheej ua haujlwm hnyav xws li kev cuam tshuam ntawm cov thee thiab kev xeb ntawm cov kua qaub dej tuaj yeem txhim kho.
II. Kev siv tau tiag tiag: Los ntawm "kev rhuav tshem ntug" mus rau "kev ua tau zoo tshaj plaws"
1. Kev txhawb nqa hydraulic "lub neej txuas ntxiv kev hloov pauv"
Tom qab cov txheej chromium plating ntawm qhov chaw ntawm hydraulic kem raug tev tawm, lub kem yooj yim xeb thiab ua tsis tiav hauv qab kev kub siab. Kev siv tshuab laser cladding tuaj yeem:
Tom qab tshem cov txheej qub tawm lawm, ib txheej cobalt-based alloy uas tuab 0.8-1.5 hli tau muab tso ncaj qha rau ntawm qhov chaw ntawm lub substrate;
Qhov nyuaj yog nce mus rau HRC 55-60 (txheej txheem chromium plating thawj tsuas yog HRC 40-45 xwb), thiab qhov kev tiv thaiv hnav tau nce ntau dua 3 zaug;
Qhov kev tiv thaiv corrosion yog qhov txhim kho zoo heev. Lub neej ua haujlwm ntawm cov kem kho qhov av hauv cov dej kua qaub hauv qhov av ncav cuag 18 lub hlis, ntau dua li daim tshiab thawj (6-8 lub hlis).
2. Qhov nruab nrab ntawm lub tshuab scraper yog "rov tsim dua tshiab"
Qhov hnav txhua xyoo ntawm lub phaj hauv qab ntawm lub qhov nruab nrab nce mus txog 15 hli, nrog rau kev hloov pauv ib txwm muaj nqi ntau dua 20,000 yuan ib chav. Cov kev daws teeb meem laser cladding siv cov khoom siv tungsten carbide particle-reinforced iron matrix composite rau cov chaw uas hnav yooj yim ntawm phab ntsa qhov. Ua tiav qhov nyuaj ntawm qhov chaw tshaj HRC 62, qhov kev tsim kho tshiab no ua rau muaj kev tiv thaiv kev hnav los ntawm 5-8 zaug. Cov ntawv thov hauv thaj chaw khawb av qhia tau hais tias lub qhov nruab nrab uas tau kho dua tshiab txuas ntxiv lub neej kev pabcuam los ntawm 6 lub hlis mus rau 24 lub hlis, thaum cov nqi kho ib tuj ntawm cov thee txo qis 40%.
3. "Kev tsim kho dua tshiab" ntawm phab ntsa sab hauv ntawm lub tog raj kheej hydraulic
Txhawm rau daws qhov teeb meem ntawm kev sib khi tsis ua haujlwm los ntawm kev khawb ntawm phab ntsa ntawm lub tog raj kheej: Lub kaw lus siv cov hmoov coaxial ua ke nrog lub laser nozzle tshwj xeeb rau cov qhov sab hauv, ua rau muaj kev sib txuas zoo hauv qhov chaw nqaim. Qhov roughness ntawm qhov chaw tom qab kho (Ra ≤ 0.8μm) dhau cov qauv kev ua haujlwm tshiab. Kev sim hauv thaj chaw ntawm lub Hoobkas siv tshuab thee qhia tau tias cov tog raj kheej kho tau ua tiav 100% kev ua haujlwm sealing thaum tus nqi tsuas yog 30% ntawm cov khoom tsim tshiab.
III. Kev Hloov Pauv Peb Zaug: Kev Lag Luam, Kev Ua Haujlwm Zoo thiab Kev Hloov Pauv Ntsuab
| qhov ntev | Cov kev qhia ib txwm muaj | Kev tsim kho dua tshiab ntawm laser cladding | Qhov txiaj ntsig ntawm kev hloov pauv |
|---|---|---|---|
| Tus nqi | Cov khoom siv tshiab kim heev yuav | Tus nqi kho (20% -50%) | Ib lub bracket txuag tau 150,000 yuan |
| Lub Sijhawm | Kev kho kom haum rau kev txiav txim tshiab (30 hnub +) | Kho hauv tsev (3-5 hnub) | Kev kaw cov khoom siv raug txo los ntawm 70% |
| Kev Ua Haujlwm | Rov qab mus rau qhov xwm txheej pib | Kev txhim kho kev hnav / kev tiv thaiv corrosion | Lub neej ntev dua 200% -300% |
| Kev tiv thaiv ib puag ncig | Kev ua qias tuaj ntawm electroplating (chromium ions) | Yuav luag tsis muaj kuab paug | Hloov cov txheej txheem electroplating lom |
IV. Txij li kev kho mus rau kev txhim kho: yav tom ntej ntawm kev tsim dua tshiab ntawm cov cav thee ntse
Nrog kev koom ua ke ntawm cov thev naus laus zis ntse, laser cladding tau mus txog qhov siab tshiab hauv kev siv tshuab thee: 1) Cov chaw ua haujlwm robotic tsis siv neeg ua rau muaj kev kho cov khoom sib xyaw ua ke xws li kem thiab lub tog raj kheej, ua kom muaj txiaj ntsig zoo dua 50%; 2) Digital twin predictive maintenance saib xyuas cov khoom siv hnav los ntawm cov sensors kom ua tiav kev kho cladding ua ntej ua tsis tiav; 3) Cov ntaub ntawv ua haujlwm gradient tsim cov khaubncaws sab nraud povtseg sib xyaw nrog cov nplaim sab nraud superhard rau kev tiv thaiv hnav thiab cov khaubncaws sab hauv muaj zog tiv thaiv cov kab nrib pleb, ua tau zoo daws cov teeb meem kev cuam tshuam-hnav ua haujlwm.